E-one Extreme Series User manual

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Service
Manual
_____________________
E/One Extreme
Grinder Pumps
240V, 60 Hz
Wireless Controls

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1
Table of Contents
Page #
1. Service Manual Overview ...........................................................................3
2. Product Introduction
Wireless: (DR & WR)............................................................................5
3. Troubleshooting (at panel, at EQD, site inspection)
Wireless: (DR & WR)............................................................................6
Site Survey (Panel) ............................................................................6
Supply Voltage Checks......................................................................7
Buck Boost Transformer....................................................................7
Operating Voltage Checks.................................................................9
Continuity Test...................................................................................10
Megohm / Insulation Integrity Test ...................................................12
Amperage Checks..............................................................................12
Site Survey (Tank).............................................................................13
Troubleshooting Charts......................................................................13
Magic Wand.......................................................................................16
Schematics .........................................................................................17
4. Core Removal/Replacement
a. DR......................................................................................................18
b. WR.....................................................................................................19
5. Start-up Procedure (inspection and testing on site) .................................20
6. Pump End/Grinder Mechanism (inspection/replacement of grinder, stator, rotor,
etc.) ................................................................................................................22
Removing the Pump Stator................................................................22
Pump Stator Inspection......................................................................25
Inspecting a Pump Rotor....................................................................27
Removing the Pump Rotor.................................................................28
Assembling the Pump/Grinder Mechanism.......................................29
Dry Well Pump Exploded View........................................................30
Wet Well Pump Exploded View........................................................31
7. EQD Disassembly and Reassembly.............................................................32
EQD Disassembly..............................................................................32
EQD Reassembly...............................................................................33
EQD Retrofit......................................................................................36

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8. Top Housing Removal and Installation
a. Top Housing Removal and Installation (DR, DH or DX) ............37
Top Housing Removal.......................................................................37
Discharge Tube Removal...................................................................38
Top Housing Reassembly and Installation ........................................40
b. Power Cable Replacement.............................................................42
9. Level Sensor (inspection/replacement of pressure switches,
equalizer, etc...)
Wireless...................................................................................................45
Level Sensor Removal.......................................................................45
Level Sensor Assembly Simulator.....................................................46
Level Sensor Test Procedure .............................................................47
Level Sensor Leak Troubleshooting & Repair ..................................48
Level Sensor Disassembly.................................................................48
Level Sensor Reassembly..................................................................51
Equalizer Field Reset (Original Style)...............................................53
Equalizer Field Reset (New Style).....................................................55
Level Sensor Exploded View.............................................................57
10. Control Cavity
(DR & WR).............................................................................................58
Control Housing Removal .................................................................58
Motor Contactor and Controls...........................................................61
Motor Cavity Water Test ...................................................................62
Motor Windings Test.........................................................................63
Transceiver Removal.........................................................................64
Transceiver & Control Bracket Wiring..............................................65
Control Housing Installation..............................................................66
11. Motor Cavity (disassembly and reassembly as well as testing) ...............67
Core and Motor Disassembly.............................................................67
Assembling the Core and Motor........................................................71
12. Mechanical Seal Assembly (installation procedures) ...............................75
13. Final Tests (run test, amp draw test, etc.) .................................................76
Motor Cavity and Seal Assembly Leak Test .....................................76
Control Cavity Leak Test...................................................................78
Test Run.............................................................................................79
Amperage Draw Test.........................................................................80

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Chapter 1 —Service Manual Overview
This manual contains information about servicing, rebuilding, and troubleshooting the Extreme-
Series grinder pumps. A thorough understanding of these products will save you valuable time
when troubleshooting and repairing Environment One Grinder Pumps. This manual is
separated into different sections/chapters to make it easy to locate the correct information
quickly. This manual contains information specific to the hardwired model. Refer to the Index in
the back of the manual to locate the pages covering the specific subject you are looking for.
7. Service Manual Overview
8. Product Introduction
9. Troubleshooting (at the panel, at the EQD, site inspection)
10. Core Removal/Replacement
a. DR & DX
b. UR, WR, WX
c. IR
11. Start-up Procedure (inspection and testing on site)
12. Pump End/Grinder Mechanism (inspection/replacement of grinder, stator, rotor, etc.)
13. EQD Disassembly and Reassembly
8. Top Housing Removal and Installation
a. Top Housing Removal and Installation (DR or DX)
b. Top Housing Removal and Installation (IR)
c. Cable Replacement (DR, UR & WR)
14. Level Sensor (inspection/replacement of pressure switches, control board, etc...)
15. Control Cavity
16. Motor Cavity (disassembly and reassembly as well as testing)
17. Mechanical Seal Assembly (installation procedures)
18. Final Tests (run test, amp draw test, etc.)
Safety Warnings
A Caution statement in this manual designates a situation that could cause equipment failure or
damage. Follow the proper safety procedures as described in the instructions.
A Warning statement in this manual designates a situation that can cause bodily harm and/or
equipment damage. Follow the proper safety procedures as described in the instructions.

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Extreme Series Station Identification Chart
Each station name is made up several different identifiers (Ex: DH272):
D: D-Series (or Drywell)
H: Hardwired Level Control connection
27: Tank Style
2: Duplex station (or 2 pumps)
or for WR231:
W: W-Series (or Wet well)
R: RF (or Wireless) Level Control connection
23: Tank Style
1: Simplex station (or 1 pump)
In this manual you will see the pumps referenced as wireless or hardwired, as those are the
main differences regarding troubleshooting. You may also see chapters referencing pump
models [Ex.: (Chapter 2a) - Product Introduction (DR, WR, DX, or WX)] to let you know what
pump style the chapter is referring to. The X is for the explosion-proof model that has yet to be
released, but will contain an RF Level Control connection.

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Chapter 2 —Product Introduction
Wireless-Communicating Models: (DR & WR)
Environment One Grinder Pumps are designed to grind and pump domestic sewage. The
grinder pumps are not designed to be small lift stations. They are not capable of handling
waters with high concentrations of mud, sand, silt, chemicals, abrasives, or machine wastes.
Environment One’s semi-positive displacement, progressing cavity pumps provide predictable
flow over a wide variety of pressures. High–torque, low–speed motors power the pumps. The
unique one–piece core assembly is interchangeable throughout E/One’s product line. These
models utilize a wireless interface between the level-sensing assembly and the motor controls.
The wireless feature utilizes a new wiring scheme between the switches and the controls, but
the basic operation is the same as the hardwired version.
Basic Operation
The grinder pump is designed to grind and pump domestic sewage. The pump is a semi-
positive displacement, progressing cavity pump. The grinder pump consists of a pump
assembly with an integral sewage grinder and shredder device. The pump traps a column of air
in the sensing column for the On–Off Pressure Switch. When water in the tank reaches the
normal turn–on level, the pressure in the sensing line opens the normally closed electrical
contact points. The Transceiver Assembly senses a change in the Switch contacts and sends
voltage on the brown wire to terminal A2 on the contactor. The contactor/relay coil is energized
and the relay contact points close, providing electrical power to the pump motor. When the
motor starts and runs, the grinder pulverizes any solids. The slurry is then pumped by the pump
rotor and stator until the liquid in the tank is lowered to the shut–off level. This reduces pressure
on the diaphragm of the on–off switch, which closes the electrical contacts in the switch, opens
the contacts in the contactor, and removes power to the motor.
In the event of a pump failure or excessive in-rush of liquid, the liquid in the basin rises and
activates an alarm pressure switch. The electrical contacts open, activating the alarm indicator
(light and buzzer). The alarm alerts the homeowner about a pump problem. The pump is again
called on to run. The pump will attempt to pump the station down to the alarm off level.

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Chapter 3 —Troubleshooting
Wireless-Communicating Models: (DR & WR)
Site information is vital to proper diagnosis of a pump failure, and getting the station back to
normal. When a pump requires service, an inspection of the site should be the first task
performed. The following procedure details the proper method for gathering the maximum
amount of data that can be collected during a service call.
Site Survey (Panel)
1. Observe the site
Record the following on the service tag.
a. Customer Information
b. Date
c. Time
d. What is the alarm status?
e. Is the pump running? (without opening the station)
2. Open the Panel
Record the following on the service tag.
a. Is the panel dry and free of moisture?
b. Have any breakers tripped?
c. Was the panel correctly installed? (penetrations on bottom, sealed conduits, etc.)
d. Is any service needed to the panel?
Figure 3 –1

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Supply Voltage Checks
The Environment One grinder pump is equipped with a 1725 rpm, 1 hp, multi-tap 120V / 240V
motor. The wireless version is only available in the 240V configuration. The operating voltage
parameters of the motor are plus or minus 10% of the specific application. This would equate to
216V to 264V in the 240V application. Refer to the chart below for supply voltage checks for the
wireless version.
Supply Voltage and Breakers 240V (wireless controls)
Color 1
Color 2
Normal
Reading
Operation
If Reading is Wrong, Check:
L1
L2
216V –264V
Incoming
Voltage to
Breaker
OK
Breaker Tripped or Off in Main Panel, Lost
Leg of Power, poor connection, damaged
wire
Red 2
Black 3
216V –264V
DBL Pole
Breaker
OK
Bad Breaker, Lost Leg of Power
Neutral
Alarm
Breaker
(Incoming)
108V –132V
Incoming
Voltage to
Breaker
OK
Breaker Tripped or Off in Main Panel, Lost
Leg of Power, Jumper Wire not
Connected
Neutral
Alarm
Breaker
(Pump
Side)
108V –132V
Alarm
Breaker
OK
Bad Breaker
Neutral
Yellow 5
108V –132V
Voltage to
Alarm
Switch OK
Loose Wire to Alarm Board or Single Pole
Breaker, Bad Alarm Board
Table 3 –1
Buck Boost Transformer
240V Application
In the event that the supply voltage on a 240V application is 208V 3 phase, a buck boost
transformer will have to be installed. By failing to install the transformer you would be
significantly shortening the life of the motor. A buck boost transformer will typically manipulate
one leg of the supply voltage. It will raise the one leg approximately 32V (240V –208V = 32V)
which would give you approximately 152V on one leg and 120V on the other combined to equal
240V.This is important to know because we are sharing one leg of the main supply voltage with
the alarm circuit which is a 120V circuit with an operating range of 108V to 132V. You must
connect the higher of the two legs to the pole of the double pole breaker that has the pump L2
(Black) wire tied to it. The pole with the pump L1 (Red) wire is the pole that is being shared with
the alarm breaker. Failure to connect the wires in this configuration will result in a high voltage
condition on the alarm circuit board subsequently resulting in failure of the circuits.

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9
Operating Voltage Checks
Voltage Test (wireless controls)
(In Liquid)
This table assumes that the unit is in a tank that has enough water to activate the alarm switch
Color 1
Color 2
Normal
Reading
Operation
If Reading is Wrong, Check:
Neutral
Blue 6
108V -
132V
Alarm Switch
On
Loose Wire in EQD, Controls, Bad Alarm Switch, Bad
Transponder or Bad Transceiver
Brown 1
Red 2
0 Volts
Pump Called
to Run
Loose Wire in EQD, Controls, or Bad Transceiver
Brown 1
Black 3
216V -
264V
Pump Called
to Run
Loose Wire in EQD, Controls, or Bad Transceiver
Yellow 5
Blue 6
0 Volts
Alarm Switch
On
Loose Wire in EQD, Controls, Bad Alarm Switch, Bad
Transponder or Bad Transceiver
Table 3 –2
Voltage Test (wireless controls)
(Out of Liquid)
This tables that the unit has pumped down and shut off on its own or is not installed in a tank
Color 1
Color 2
Normal
Reading
Operation
If Reading is Wrong, Check:
Neutral
Blue 6
0 Volts
Alarm Switch
Off
Controls, Bad Alarm Switch, Bad Transponder or Bad
Transceiver
Brown 1
Red 2
216V -
264V
Pump not
Called to Run
Loose Wire in EQD, Controls, or Bad Contactor
Brown 1
Black 3
0 Volts
Pump not
Called to Run
Loose Wire in EQD, Controls, or Bad Transceiver
Yellow 5
Blue 6
108V -
132V
Alarm Switch
Off
Loose Wire in EQD, Controls, or Bad Transceiver, or
Bad Transponder
Table 3 –3

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Continuity Tests (wireless controls)
All continuity readings should be taken after the power is turned off and verified with a
voltmeter. With the pump power off, set an ohmmeter (Wavetek #5XP or equivalent) to the
appropriate scale listed on the note above the specific chart (auto-ranging meters must be
manually set). Identify the wires coming from the pump into the panel. All of the test points
listed below refers to pump wires only. Allow at least 5 seconds for the meter to obtain a stable
reading. Note any incorrect readings on the service tag. Note: The ground to blue and
ground to yellow checks below are true for two relay configuration simplex, duplex
Panels. Four relay configuration Simplex boards, Protect & Protect Plus panels will show
an open on these checks whether in or out of water.
Note: The following checks will be done with the multi-meter in the 2000k or 2M range.
Color 1
Color 2
Normal
Reading
Operation
If Reading is Wrong, Check:
Green 4
Brown 1
Red 2
1 or OL =
Open
Circuit
No Shorts to
Ground
Water in controls, wet or corroded EQD, underground
cable shorted, moisture in control panel
Green 4
Black 3
1 or OL =
Open
Circuit
Motor
Water in motor, field shorted to Ground
Green 4
Yellow 5
Blue 6
.000
Closed
Circuit
Relay on
Transceiver
Relay bad on transceiver board, loose wire in controls or
EQD
Brown 1
Yellow 5
Blue 6
1 or OL =
Open
Circuit
No Short to
Manual Run
Water in controls, wet or corroded EQD, underground
cable shorted, moisture in control panel, PTR shorted or
closed
Yellow 5
Blue 6
.000
Closed
Circuit
Relay on
Transceiver
Relay bad on transceiver board, loose wire in controls or
EQD
Table 3 –4
Note: The following checks will be done with the multi-meter in the 200K
Color 1
Color 2
Normal
Reading
Operation
If Reading is Wrong, Check:
Brown 1
Black 3
1.5
Contactor Coil
Coil open on contactor, Transformer bad on
Transceiver, loose wire in controls or EQD
Brown 1
Red 2
2.3
Contactor
Coil/Transformer
on Transceiver
Coil open on contactor, Transformer bad on
Transceiver, loose wire in controls or EQD
Red 2
Black 3
0.8
Transformer on
Transceiver
Transformer bad on Transceiver, loose wire in controls
or EQD
Table 3 - 5

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12
Megohmmeter / Cable Insulation Integrity Check
1. Separate EQD’s and disconnect the Tray Cable wires from the Alarm Panel.
2. Using a 500V Megohm meter, check for shorts between all wires.
Good
Marginal
Bad
500M or higher
Between 200M & 500M
Below 200M
3. If shorts are found, remove the EQD insert from the cable and perform test again.
4. If shorts go away, then replace the insert and perform test again.
5. If shorts do not go away then the Tray Cable will need to be replaced.
Amperage Checks
The use of a clamp on amp meter can be helpful in identifying problems such as a
restricted/blocked discharge line, blown Stator, faulty Check/Anti-siphon valve, etc...
1. Set the clamp-on amp meter to the appropriate scale.
2. Hook the probe around the Black power lead in the alarm panel.
3. With the power on, fill the tank until the pump operates, or depress the push to run
switch in the panel.
4. Read the current directly. Refer to the following table for troubleshooting.
Table 3 –6
The figures shown are averages and meant to be used for approximation since motors, voltages
and amp meters vary. The table displays a comparison of back pressure (psi), flow (GPM),
current draw (amperes) and head (feet of water pressure). By knowing the current draw, you
may discover a restricted or blocked discharge line, blown pump Stator, high head operation,
etc.
A jammed grinder may trip the circuit breaker or cause the overload protector to cycle. This
causes the pump to cycle on and off, and eventually results in an alarm condition. A torn or
worn out pump Stator results in a “runs but does not pump” condition and eventually, as the
water rises, causes an alarm. Replace the Stator and, if necessary, the Rotor.
Amps @ 240V
(@ 120V)
PSI
Head
(ft)
GPM Comments
4.9 (9.8) or less 0 0 0 Worn Stator
5.6 (11.2) 10 24 14 Normal
5.8 (11.6) 20 46 13 Normal
6 (12) 30 70 12 Normal
6.2 (12.4) 40 92 11 Normal
6.5 (13) 50 115 10 Normal
6.8 (13.6) 60 138 9 Normal
7.1 (14.2) 70 161 8 Normal
7.4 (14.8) 80 184 7.5 Normal
8 (16) or higher
90+ 207+ varies Plugged Discharge Line or bad bearings
over 15 (30) 0 0 0 Jammed Grinder or Shorted Motor

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Site Survey (Tank)
1. Open the Tank and Inspect
Record the following on the service tag.
a. Is the tank/access way flooded?
a. If yes, where did the water enter?
b. Was the EQD below water?
c. Is the equalizer hung properly?
d. Is the water tight connector nut tight?
2. Disconnect the EQD and Inspect
Record the following on the service tag.
a. Is the EQD Dry?
b. Is the EQD assembled correctly?
3. Repeat the power-off Continuity Checks at the EQD.
Troubleshooting Charts
The following troubleshooting tips will help diagnose more frequent causes of some grinder
pump problems.
Alarm On –Pump Running but not Pumping
Possible
Causes
Troubleshooting Steps
Blocked
Discharge Line,
Worn Stator or
leak in pump
discharge
assembly
Check the amperage. If the amperage is high (8 amps or higher),
turn off the pump and check the discharge line for blockage.
Confirm that the pump has not been damaged by disconnecting the
discharge piping and recycling the fluid in the tank. Turn the pump
power on and check the amperage. If the amperage remains high,
replace the pump and return the failed pump to shop for possible
repair. If amperage returns to normal, clear blockage in discharge
line and re-check amperage.
If the amperage is low (4.9 amps or less), the pump must be pulled
and the Stator (and possibly the rotor) replaced. Visually inspect
the Check/Anti-siphon valve for cracks and the discharge line for
ruptures. Repair or replace if necessary. The cause of the failure
must be determined and corrected before reinstallation or the
pump will fail prematurely again. Chapter 6 –Pump End, describes
how to identify and correct causes of Stator and Rotor wear.
Table 3 –7

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Alarm On —Pump not Operating
Possible
Causes
Troubleshooting Steps
Incorrect Voltage
Check the voltage at a location nearest the pump, such as the
junction box or electrical quick disconnect (EQD) plug. The correct
voltage is listed on the pump nameplate. Note: Voltage must be
within 10 percent of nameplate voltage (240V: 216 to 264V; 120V:
108V to 132V). 208V requires a transformer to boost voltage.
Plugged
Equalizer
Check the Equalizer Tube connected to the Equalizer and make
sure that it isn't crimped or pinched.
Low Fluid Level
Check the tank for sufficient fluid to activate the alarm. Insufficient
fluid may indicate a problem with the alarm wiring, the alarm
sensing line or the alarm switch. Chapter 9 –Level Sensor and
Chapter 10 Control Cavity, describes the process for checking the
alarm wiring and controls.
Wet or Corroded
Controls
Inspect the electrical controls. Replace any wet or corroded
controls. See Chapter 10 –Control Cavity.
Inoperative
Control
Test the controls as described in Chapter 10 –Control Cavity
Table 3 –8
Alarm Activates Frequently
Possible
Causes
Troubleshooting Steps
High Flow
The incoming flow is greater than the pump can handle. Infiltration,
a sump pump, a hot tub or any other device that causes excessive
water flow can cause high flow.
Plugged Vent or
Equalizer Tube
Check the Vent and the Equalizer Tube. A plugged or partially
plugged Vent or Equalizer Tube may cause the alarm to activate
frequently. Replace the Equalizer Tube if kinked or damaged.
Level Sensor
Leak
Pull the pump out of the tank. Inspect the Level Sensors for leaks
and debris; use Level Sensor test to check for leaks.
Line Blockage or
Worn Stator
Check the amperage. If the amperage is high, look for a line
blockage. If the amperage is low, inspect the Stator for excessive
wear.
Underground
Wire Damage
Check the Tray Cable wiring for cuts, breaks and shorts. Use a
Megohm Meter to check for shorts between each pair of leads.
Replace the Tray Cable if a short is found.
Table 3 –9

15
Noisy Pump
Possible
Causes
Troubleshooting Steps
Normal
Operation
The pump may be grinding up material. Wait a few minutes. If the
pump does not quiet down, remove the core and clean the basin.
Low Voltage
Check the voltage level. The voltage is listed on the pump
nameplate. Note: Voltage must be within 10 percent of nameplate
voltage (240V: 216V to 264V; 120V: 108V to 132V). 208V requires
a transformer to boost voltage.
Blocked
Discharge
Check the amperage. If the amperage is high (8 amps or higher on
240V or 16amps or higher on 120V), turn off the pump and check
the discharge line for a blockage. Confirm that the pump has not
been damaged by disconnecting the discharge piping and recycling
the fluid in the tank. Turn the pump power on and check the
amperage. If the amperage remains high, replace the pump and
return the failed pump to shop for possible motor repair. If it returns
to normal, clear discharge and re-check amperage.
Damaged Stator
Check the Stator for holes or tears. Chapter 6 –Pump End,
describes the pump Stator inspection procedure.
Worn Motor
Bearing
Remove the pump Stator and hand–rotate the shaft. If the shaft
turns roughly, replace the pump. Return the failed pump to the
shop and replace the motor bearings.
Table 3 –10

16
Extreme Magic Wand
Figure 3 -2 Figure 3 - 3
The Extreme Magic Wand is a very useful tool for diagnosing and identifying faults that may be
occurring on a Wireless pump. It is very easy to use and it will tell the condition or status of the
switches, transceiver and transponder. The pump must have power applied to it in order to test
it with the Magic Wand. Turn on the power to the Magic Wand and position the end of the wand
as described above to test the pump. This test can be performed on a pump either in or out of a
station.

17
Wiring Schematic for 240V wireless

18
Chapter –4a Core Removal/Replacement
DR (Dry Well versions)
1. Open the control panel and shut off all power, going to the pump and the alarm system.
2. Open the lid to the station.
3. Disconnect the EQD. If the Tray Cable side EQD is wet or has moisture in it, then the
EQD insert must be replaced and the source of moisture determined and corrected
before connecting a new pump to it.
4. Close the stainless steel ball valve, which is done by using the core wrench. The core
wrench has a bent handle on one end of it. Take the bent end and insert it into the hole
on the handle of the valve and push down, so the handle is now horizontal. The valve is
now closed.
5. Now use your core wrench and turn the bolt in the middle of the top housing 1/3 turn to
the left to release the holding tabs.
6. Utilizing the rope attached to the pump, pull the pump out of the station (the pump
weighs approximately 100lb). Note: DO NOT pull the pump out of the station by the
discharge tube, equalizer tube, or the power cable.
7. Lower the new pump into the tank
8. Now use your core wrench and turn the bolt in the middle of the top housing 1/3 turn to
the right to engage the holding tabs.
9. Utilizing the core wrench, open the valve.
10. Perform start up as described in Chapter 5.